Handrails and Fabrication Methods

ABSTRACT

Arrangements including pressing arrangements of dies are provided as well as processes for pressing a contour into tubular material. Handrails and docks having a handrail thereon are provided. Processes for disembarking/embarking between a floating vessel and a dock are provided.

CLAIM FOR PRIORITY

This application claims priority to U.S. Provisional Patent Application Ser. No. 60/926,378 which was filed on Apr. 26, 2007, the entirety of which is incorporated by reference herein.

TECHNICAL FIELD

The present disclosure relates generally to railing fabrication methods and more particularly to handrails, and metal fabrication methods.

BACKGROUND

Handrails are utilized on a daily basis for negotiation of stairs and ramps. Typically, handrails are outdoors and they must suffer with the elements of outdoors, standing the test of time through winter, summer, and fall. As such, it is desired that handrails are durable, and at the same time provide a surface that can be easily grasped and released. The present disclosure provides handrails heretofore unknown in the art, as well as methods for producing rails and tubular bodies that can be used for other purposes beyond traditional handrail use.

SUMMARY

Arrangements of dies are provided that can include a first die and a second die, the dies having adjoining surfaces complimentary to one another, wherein each of the dies further define opposing openings configured to receive material for pressing; and wherein a first surface of the opposing opening of the first die defines a different shape than a second surface of the opposing opening of the second die.

Pressing arrangements of a plurality of dies are provided with the arrangement including: a plurality of first dies aligned across from a plurality of second dies, the dies having adjoining surfaces complimentary to one another, wherein each of the dies further define opposing openings configured to receive material for pressing; and wherein the plurality comprises a first group of first and second dies having first surfaces of the opposing openings of the first dies defining a different shape than second surfaces of the opposing openings of the second dies.

Processes for pressing a contour into tubular material are provided that can include aligning the tubular material between two sets of dies, one of the sets comprising substantially planar pressing surface in relation to a relatively non-planar pressing surface of the other set; and pressing one set toward the other set to form a contour on the exterior of the tubular material.

Handrails are provided that can include both vertical and horizontal portions, the vertical portion supporting the horizontal portion, wherein the at least one of the portions comprises peripheral exterior surfaces, one of the surfaces being relatively planar in comparison to another surface in one cross section.

Docks having a handrail thereon are provided with, the handrail comprising both vertical and horizontal portions, the vertical portion supporting the horizontal portion, wherein the at least one of the portions comprises peripheral exterior surfaces, one of the surfaces being relatively planar in comparison another surface in one cross section.

Processes for disembarking/embarking between a floating vessel and a dock are provided, with the process including stabilizing oneself with a handrail extending from the dock and transitioning between the dock and the floating vessel.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the disclosure are described below with reference to the following accompanying drawings.

FIG. 1 are exemplary dies of the present disclosure.

FIG. 2 is an exemplary arrangement of two dies according to an embodiment.

FIG. 3 is a cross-section of a lower die of FIG. 3 according to an embodiment.

FIG. 4 is an exemplary arrangement of the dies of FIG. 1 according to an embodiment.

FIG. 5 is an arrangement of dies having a blank therebetween according to an embodiment.

FIG. 6 is an arrangement of dies between a press having a blank therebetween according to an embodiment.

FIG. 7 is the arrangement of FIG. 6 at a finished position according to an embodiment.

FIG. 8 is a piece part according to an embodiment.

FIG. 9 is a pressing arrangement having a blank therebetween according to an embodiment.

FIG. 10 is the fabrication of a piece part according to an embodiment.

FIG. 11 is a handrail supported by a dock assembly according to an embodiment.

FIG. 12A is a piece part for a land-based application according to an embodiment.

FIG. 12B is another orientation of the piece part of FIG. 12A according to an embodiment.

FIG. 12C is another piece part for a land-based application according to an embodiment.

FIG. 12D is another piece part for a land-based application according to an embodiment.

DESCRIPTION

Example embodiments of the rail assemblies and metal fabrication methods including methods of manufacturing rail assemblies are described with reference to FIGS. 1-12. Turning first to FIG. 1, a plurality of dies are shown, particularly a series of ten (10) dies that can include first and second dies such as upper dies A and lower dies B. This can be referenced as a pressing arrangement of a plurality of dies, for example. The first dies can be aligned across from the second dies.

According to an embodiment, upper dies A can be formed from a blank piece of tool steel, the blank having similar size as the blank used to form lower die B. These dies can be approximately 4″ wide and approximately 4″ tall and on average about 1″ in depth, for example. Alternative sizes of the dies, depending, for example, on the material to be processed or the desired processing, are contemplated. According to an example embodiment, die piece A can have an opening formed in the middle approximately 1.5″ in diameter and be split longitudinally across the opening. Lower dies B can have an opening approximately 1.375″ in diameter formed in the center, and then split through the opening to form two pieces as in upper die A, for example. Upper die A be configured to press material into lower die B.

Referring to FIG. 2, dies A and B can be associated with one another, wherein die A is above die B, or die B is above die A. It is contemplated that where dies A and B converge or interface, their structure at the interface may compliment one another. As an example, die A may have adjoining surface 24 and die B can have adjoining surface 22. According to an example embodiment, surfaces 22 and 24 may well be relatively planar in relation to one another.

Die A may define an opening 28 and die B can define opening 26 with both openings 28 and 26 configured to receive material for pressing. As such the openings can oppose one another when operatively aligned. As an example, opening 28 can have a surface 29 and opening 26 can have a surface 30. Surface 29 can define a different shape than surface 30. Surface 29 can be relatively planar when compared to surface 30. As an example, surface 29 can be a sheer, flat opening that extends from the lateral face of die A to the other lateral face. Surface 30, for example, such as surface 30 of die B can have a contour to the interior wall of its opening, such as a convex contour.

Referring to FIG. 3, this interior wall is shown as a cross-section of FIG. 2. This contour of the interior face of the opening of die B is shown in FIG. 3 as contour 30. Contour 30 can be an elevated portion within the center of the opening of die B extending from lateral face 32 to lateral face 34 of die B.

Referring to FIG. 4, in accordance with an example aspect, a plurality of dies can be arranged in groups. Pressing arrangement 10 can include a group 44 and end group 42. Group 42 can be on the periphery of group 44 and group 44 can include dies A and B, with these dies having opening surfaces of different shapes. Group 42 can include dies having like opening surfaces such as dies A. According to an embodiment, upper dies A can be opposed to one another at end portions 42, for example. In accordance with example implementations, having end portions 42 configured in this manner may facilitate processing by alleviating at least some of the shifting of the blank as it is being formed. Dies A and B can be placed opposing one another throughout the distance between end portions 42, for example. While shown in FIG. 4 that a series of three (3) opposing portions of A and B are shown, the present disclosure contemplates various configurations of A opposing B, such as with blank A's in between sections with A opposing B, and/or multiple A's and B's in a series. For example, depending upon the desired amount of contoured piece parts to be shown later, many alternative sequences of A and B may be utilized.

Referring to FIG. 5, a piece part 50 such as tubular material can be aligned between two sets of dies, such as between upper dies A and lower dies A and B. This piece part can comprises tubular steel, tubular aluminum, stainless steel, and/or aluminum electric weld, for example. The tubular steel can be round-sided tubular steel; however, tubular steel having flat sides is also contemplated. According to an example implementation, flat-sided tubular steel may be processed utilizing dies having complementary flat-sided interiors. As an example, square tubular steel may be processed using dies having square interior openings. The tubular steel may be treated or it can be tubular aluminum, such as anodized aluminum, or any form of tubular steel may be utilized.

Referring to FIG. 6, blank or piece part 50 is shown in between dies A and B with pressing apparatus 60 to be applied to upper dies A, forcing the fabrication of portions of part 50 in accordance with dies B. Dies can be pressed together, one set toward the other, to form a contour on the exterior of the part. According to an example fabrication method, pressing device 60 may be configured to apply upwards of as much as 1500 lbs per square inch pressure to a blank having a 1.5″ diameter. The tubing itself, or part 50, may have walls as thick or as thin as 1/32 inch or as large as ¼ inch. In accordance with exemplary embodiments, pressing assembly 60 is shown in the first position. Referring to FIG. 7, pressing assembly 60 is shown in the second or pressed position, wherein contours of die B are shown formed within piece 50. Referring to FIG. 8, a processed piece 50 is shown, having contours 80 on at least one side of piece 50. Contours 80 can include sets of peaks and valleys in one cross section. As an example, piece 50 can be tubular material and upon processing the tubular material can have a contour therein. The material can have peripheral exterior surfaces with one of the surfaces being relatively planar in comparison to the other surface in one cross section.

Referring now to FIG. 9, according to an embodiment of the disclosure, part 90 can have portions in non-linear relation to one another such as the form of a U-shaped or U-bent piece of tubular material with one portion being substantially normal in relation to another portion. The U-bent tubular material may have two longer extending portions and a short connecting portion therebetween, for example. In accordance with at least one embodiment, one of the extending portions can be placed between dies as shown and pressed to form contours on the interior facing side. The piece may then be rotated or positioned further down the extending portion to provide even further contours along that extending portion. Referring to FIG. 10, the piece may then be rotated to a position wherein the shorter connecting portion is placed between the dies and contours are placed along the interior walls of that connecting portion of the U-shaped blank material. According to an exemplary embodiment, a handrail may be formed in this fashion.

Referring now to FIG. 11, a handrail 111 can include both vertical and horizontal portions such as two extending portions 110 and a connecting portion 112. As an example, extending portions 110 can be considered vertical portions and connecting portion 112 considered a horizontal portion. At least one of the portions can include peripheral exterior surfaces, one of the surfaces being relatively planar in comparison to another surface in one cross section.

According to another implementation, both horizontal and one vertical portion can include interior contours. In a depicted embodiment, the horizontal portion can extend relatively normally from the vertical portion. According to example implementations, rail 111 can have vertical heights of 8, 16, or 32 inches relating to the vertical portions, and widths of 12 inches relating to the horizontal portions. According to exemplary embodiments, connecting portion 112 can provide at least a 7″ distance between extending portions 110. To the extending portions 110 a flange 114 can be provided to connect the rail assembly to a substrate.

In the exemplary embodiment shown in FIG. 11, the substrate can be dock 116, such as a floating dock. Flanges 114 can be rounded or square, for example, the top edges of flanges 114 can be chamfered to prevent any cuts or scrapes when contacted. According to the example shown embodiment of FIG. 11, rail assembly 111 may have contoured surfaces on the interior facing portions of portion 110 proximate the water edge of the dock, and portion 112 on the interior facing wall of connecting portion 112, while portion 110 farthest from the water edge of the dock remains planar, for example. As such rail 111 can be aligned substantially normally to the edge of dock 116. To the portion proximate the waters edge of the dock can be coupled reflective material.

In accordance with an example implementation, rail 111 may be utilized to assist during the docking of watercraft and/or rail 111 may be utilized to assist watercraft passengers during embarking and/or disembarking. According to example implementations, between a floating vessel and dock 116 a person may stabilize themselves with rail 111. Upon stabilizing oneself, the person can transition between dock 116 and the floating vessel, for example. Rail 111 can be configured to extend from the upper surface of the dock without extending beyond the outer perimeter of the dock. An advantage of at least one embodiment of rail 111 is that it can allow a watercraft to approach a dock having rail 111 attached thereto without rail 111 damaging the exterior of the watercraft.

According to another implementation, the vessel may be stabilized proximate dock 116. As an example, a vessel occupant, upon approaching dock 116 may grasp rail 111 and retrieve the vessel toward or proximate dock 116.

Referring now to FIGS. 12A through 12D, land-based applications of rail assembly 120 are shown. For example, a rail assembly 120 can be coupled to a substrate such as steps or a raised wall, for example, referring to FIG. 12A. FIG. 12B is another view of assembly 120. FIG. 12C is yet another embodiment of the assembly wherein the extending portions 110 are of different lengths, while the connecting portion 112 is connected at angles to extending portions 110 accommodating a rising step level. Interior surfaces of extending portions 110 can both be contoured while the interior portion of connecting portion 112 is contoured as well. Referring to FIG. 12D, another embodiment of rail assembly 120 is shown wherein the rail assembly extends between more than one step. Accordingly, connection portion 112 may have a length that extends longer than extending portions 110 in such an embodiment. 

1. An arrangement of dies comprising: a first die and a second die, the dies having adjoining surfaces complimentary to one another, wherein each of the dies further defines opposing openings configured to receive material for pressing; and wherein a first surface of the opposing opening of the first die defines a different shape than a second surface of the opposing opening of the second die.
 2. The arrangement of claim 1 wherein the first surface is planar relative to a non-planar second surface.
 3. The arrangement of claim 1 wherein the adjoining surfaces are relatively planar to one another.
 4. (canceled)
 5. The arrangement of claim 1 wherein the non-planar second surface is convex in one cross section.
 6. A pressing arrangement of a plurality of dies, the arrangement comprising: a plurality of first dies aligned across from a plurality of second dies, the dies having adjoining surfaces complimentary to one another, wherein each of the dies further defines opposing openings configured to receive material for pressing; and wherein the plurality comprises a first group of first and second dies having first surfaces of the opposing openings of the first dies defining a different shape than second surfaces of the opposing openings of the second dies.
 7. The arrangement of claim 6 wherein the arrangement further comprises a second group of first and second dies, the first and second dies of the second group having different surfaces of the opposing openings than the surfaces of the opposing openings of the second group.
 8. (canceled)
 9. The arrangement of claim 6 wherein the dies of the second group are arranged on the periphery of the dies of the first group.
 10. A process for pressing a contour into tubular material comprising: aligning the tubular material between two sets of dies, one of the sets comprising a substantially planar pressing surface in relation to a relatively non-planar pressing surface of the other set; and pressing one set toward the other set to form a contour on the exterior of the tubular material.
 11. The process of claim 10 wherein the contour comprises sets of peaks and valleys in one cross-section.
 12. The process of claim 10 wherein portions of the tubular material are non-linear in relation to one another.
 13. The process of claim 12 further comprising pressing one of the portions to form the contour in the one portion and rotating the material through the dies then pressing another portion to form the contour in the other portion. 14-20. (canceled)
 21. A dock having a handrail thereon, the handrail comprising both vertical and horizontal portions, the vertical portion supporting the horizontal portion, wherein at least one of the portions comprises peripheral exterior surfaces, one of the surfaces being relatively planar in comparison to another surface in one cross section.
 22. (canceled)
 23. The dock of claim 21 wherein the handrail is aligned relatively normal to the edge of the dock.
 24. A process for disembarking/embarking between a floating vessel and a dock, the process comprising: stabilizing oneself with a handrail extending from the dock; and transitioning between the dock and the floating vessel.
 25. The process of claim 24 wherein the dock is floating.
 26. The process of claim 24 further comprising stabilizing the vessel proximate the dock, the stabilizing of the vessel comprising a vessel occupant grasping the handrail and retrieving the vessel toward the dock.
 27. The process of claim 26 wherein the handrail comprises both vertical and horizontal portions, the vertical portion supporting the horizontal portion, wherein at least one of the portions comprises peripheral exterior surfaces, one of the surfaces being relatively planar in comparison to another surface in one cross section.
 28. The process of claim 27 wherein the vessel occupant grasps the other surface of the handrail.
 29. (canceled) 